MEng 5265 Process Planning &

Product Costing
Introduction,
Basic Concepts of Process Planning,
Logical Design of A Process Plan,
Computer-aided Process Planning.

Process planning
Design is to answer what will be produced;
Process planning is to answer how to produce
Process planning acts as a bridge between
design and manufacturing by translating
design specifications into manufacturing
details

1/9/2015

PRODUCT REALIZATION
Product design

Process planning

Process,
machine
knowledge

Operation programming

Verification

Scheduling

Execution

Scheduling
knowledge

PROCESS PLANNING
Also called: manufacturing planning, process planning, material
processing, process engineering, and machine routing.

Which machining processes and parameters are to be

used (as well as those machines capable of
performing these processes) to convert (machine) a
piece part from its initial form to a final form
predetermined (usually by a design engineer) from an
engineering drawing.
The act of preparing detailed work instructions to
produce a part.
How to realize a given product design.

INTERACTION OF PLANNING FUNCTIONS

GEOMETRIC REASONING
global & local geometry
PROCESS SELECTION
process capability
process cost
CUTTER SELECTION
available tools
tool dimension and geometry
geometric constraints
MACHINE TOOL SELECTION
machine availability, cost
machine capability

SETUP PLANNING
feature relationship
approach directions
process constraints
fixture constraints

FIXTURE PLANNING
fixture element function
locating, supporting, and
clamping surfaces
stability
CUTTER PATH GENERATION
feature merging and split
path optimization
obstacle and interference
avoidance

PROCESS PLAN
Also called : operation sheet, route sheet, operation planning
summary, or another similar name.
The detailed plan contains:
route
processes
process parameters
machine and tool selections
fixtures
How detail the plan is depends on the application.
Operation: a process
Operation Plan (Op-plan): contains the description of an
operation, includes tools, machines to be used, process
parameters, machining time, etc.
Op-plan sequence: Summary of a process plan.

FACTORS AFFECTING PROCESS PLAN SELECTION

Shape
Tolerance
Surface finish
Size
Material type
Quantity
Value of the product
Urgency
Manufacturing system itself

PROCESS PLANNING CLASSIFICATION

MANUAL
COMPUTER-AIDED
VARIANT
GENERATIVE
AUTOMATIC

Design understanding
Geometric reasoning capability

Basic steps of process planning

Analysis of part requirements
Selection of raw work piece
Determining manufacturing operations and their
sequences
Selection of machine tools
Selection of tools, work holding devices, and
inspection equipment
Determining machine conditions (cutting speed, feed
and depth of cut) and manufacturing times (setup
time, lead time, and processing time)

1/9/2015

PROCESS PLANNING STEPS

Study the overall shape of the part. Use this information
to classify the part and determine the type of workstation
needed.
Thoroughly study the drawing. Try to identify every
manufacturing features and notes.
If raw stock is not given, determine the best raw material
shape to use.

Identify datum surfaces.

Use information on datum
surfaces to determine the setups.
Select machines for each setup.
For each setup determine the rough sequence of
operations necessary to create all the features.

PROCESS PLANNING STEPS

Sequence the operations determined in the previous
step.

Select tools for each operation. Try to use the same

tool for several operations if it is possible. Keep in mind
the trade off on tool change time and estimated
machining time.
Select or design fixtures for each setup.
Evaluate the plan generate thus far and make necessary
modifications.
Select cutting parameters for each operation.
Prepare the final process plan document.

REQUIREMENTS IN MANUAL PROCESS PLANNING

ability to interpret an engineering drawing.

familiar with manufacturing processes and practice.

familiar with tooling and fixtures.

know what resources are available in the shop.
know how to use reference books, such as
machinability data handbook.
able to do computations on machining time and cost.
familiar with the raw materials.
know the relative costs of processes, tooling, and raw
materials.

Logical Design of a Process Plan

1. Preliminary Analysis of a Mechanical Part
Task 1: what info. Does a part print provide?

Job, Sub job & Operation

Associated Surfaces
The highest degree of accuracy on a given machine tool is
obtained through using associated surfaces grouping.

a group of surfaces in a part which have functional relations

between them, e.g. tolerances of position or orientation. Such a
grouping of surfaces is called 'associated surfaces

Information to consider to define the sequence of

machining operations needed to produce the part.
geometric shape
dimensions and their tolerances
geometric tolerances
surface roughness
material type and its hardness
size of the raw material (given by its tolerance A)
number of parts in the batch (1200),

Analysis
The nature of the material gives an indication of the type of
machining processes to be used. In this example, material from
normal casting does not require special machining processes, i.e. it
can be produced by conventional technologies, without the need for
grinding. . .
The general shape of the part shows good rigidity, therefore, since
its
stability in processing is guaranteed, no special means have to be
designed
for its clamping on a fixture.
The required level of accuracy is not high and it can be obtained by
conventional machining processes, without a need to use grinding or
Similar finishing processes.
The required number of parts in the batch is of medium size which
does not justify special fixtures. This is advantageous from an
economic point of view.
The types of machine tools needed are those for turning, boring
and drilling commonly used in manufacturing.

Logical Design of a Process Plan

1. Preliminary Analysis of a Mechanical Part
Task 1: what info. Does a part print provide?

2. Selection of Machining Processes, Tools and Cutting

Parameters
Table 1. Passes and tools selected for each operation
Feature to
be
machined

Design specifications

Passes and tools

Roughing

finishing

1
2

Eventually
miller or
surfacing tool

3
4

Drill

Tool on bar

Number of
tools
Finishing
Drill

Miller or
surfacing tool

1 or 2

Countersinking
tool

Reamer

Tool for
chamfering

3. Grouping of Processes into Jobs

A succession of set-ups for executing the sequence of
operations would produce an undesirable stack-up of
tolerances.
For example. if surfaces (2)and (4)have to be perpendicular
with a tolerance of 0.02, or, in other words, become associated
surfaces, both surfaces should be machined in the same fixture
on a lathe.
Because grouping also has an economic impact, it is advisable in
this case to associate surface (5) with the group (2-4) in order
to be processed in the same job.
A similar logic is applied to the group (1+3); this has no obvious
tolerance relations. but it is more economical to produce the
surfaces in the same job.

4. Selection of Machine Tools

The main criteria of selection are:
the number of tools necessary to carry out the different operations;
the size of the batch which has to be considered in relation to the
set-up time; and
the accuracy of the selected operations.
a lathe would be better for job (2+4+5) than a boring machine,
where the number of tools to be used and the difficulty of adjusting the
tools is much more critical.
Similar considerations apply to job (1+ 3) where a choice has to be
made between drilling machines of different kinds, such as:

a sensitive hand drilling machine,

a rotating head drilling machine,
a multi-spindle drilling machine,
boring machines in line, etc.

5. Sequencing The Operations According To Precedence

Relationships (Anteriorities)

The different categories of anteriorities can be classified in the

following way:
dimensions with a datum as anteriority;
geometric tolerances with data references as anteriorities;
technological constraints in order to execute sequences of operations
properly; and
economic constraints which reduce production costs and wear or
breakage of
costly tools, etc.

Examples of Anteriorites

Fig. Anteriorities: case of a dimensional precedence

The above figure illustrates the case of a dimensional precedence: surface

F1 being dimensioned in relation to the rough surface B1, it is logical to
execute surface F1 before surface F6 (also because of the tighter tolerances
0.3). If for certain reasons, F6 has to be executed before F1, a transfer of
dimensions would be necessary and a reduction of tolerances would be the
result.

Examples of Anteriorites ..contd

Fig. Anteriorites: case of a geometrical precedence

a geometric anteriority where the tolerance of coaxiality of hole (2)is

referred to shaft (1), taken as a datum and therefore an anteriority.

Examples of Anteriorites ..contd

Anteriorities: case relating to the choice of a datum.

an important practical case relating to the choice of a datum between a centering
pin and a plane. The anteriority should go to the plane because when using the pin,
the error of positioning is the sum of the tolerances of the hole (IT), plus the
clearance between the minimal diameter of the hole and the diameter of the pin (J),
plus the tolerance on the position of the plane.
On the other hand, using the plane as an anteriority, the only error comes from the
error on the distance between the plane and the centre of the hole. Therefore, the
error in the case of the pin taken as first datum is increased by (IT +J).

Examples of Anteriorites ..contd

Anteriorites: case of a technological constraint

an example of a technological constraint. This anteriority says that a hole

having the smallest diameter or the longest depth has to be machined before
another hole of a larger diameter or a lesser depth. This is because the
straightness of a thinner hole or of a more precise hole can be impaired by
the larger or less precise hole when they intersect (e.g. H7 has to be
produced before (H11).

Examples of Anteriorites ..contd

Anteriorites: case of a burr

two cases where burrs are not allowed in a precise hole. In one case,
burrs are not accepted in hole (1) and therefore chamfer (3) has to be
executed before hole (1). In the other case, hole (2) has to be executed
before hole (1) because burrs are not allowed in hole (1).

Examples of Anteriorites ..contd

Anteriorites: case of economical constraints

economical constraints. In one case, drilling of two coaxial holes could be

performed by drilling the long and small hole first. However, by drilling the
large hole first, the length and time of processing is reduced and time
spent on the large hole is not influenced by the presence of the small hole.
Therefore, it is more economical in fact to drill the large hole first. In a
second case, it is more economical to finish surface (2) first so that surface
(1) would not be damaged.

Discussion Session !!
discuss within your group and prepare table of
anteriorities for the part in this example


Table of Anteriorities

Operations

Anteriorities
Dimensional

Geometrical

Technological

4F

2F

Orthogonal

1F
2R

Economical
41/2F economy
of machining

2F

B1

3F

2F

2R
1F

4R
41/2F

4R

4F
5F

F = finish. R = rough

B2
2F
2F

41/2F
5F

2F, protection of tool

5F, no burrs
41/2F economy
of machining


Matrix of Anteriorities
Execute these operations

Before Executing these operations

1F

2R

1F

2F

3F

4R

4F

5F

2R

2F
3F

41/2
F

Levels

1F

2R

2F

3F

4F

1F

3F

4R

4R
41/2F

4F

5F

41/2F

5F

2R

2F

5F

Order of precedence 4R 41/2F

Job (1) : (2) + (4) + (5) (turning)

4F

Job (2) : (1) + (3) (drilling)

6.

Selection

of

Workpiece Holders
References

and

Dimensional

Data

3-2-1 (six points) principle - consists of defining six points of contact on the part
which define its location uniquely, i.e., if the part is removed from its jig, it can be
replaced exactly in its former position. For parts in a batch, it means that they are
all located in an identical manner in relation to the machine reference system.

Workpiece Holders and Dimensional Data

References

contd

Table 4. selection of locating points on isostatic jig

Surf.
Mach.

Dist. To
raw
material

(2)

(4)

Surf. Of
contact

B1

Center
2

B2

Dimens./angul.
tolerance

Max. no. of
No. of contacts
contacts and
chosen and
d.o.f. cancelled d.o.f. cancelled

Type of
jig

Dim.: 1.6
Ang. for Rx :
1.6/80 = 0.02
Ang. for Ry :
1.6/80 = 0.02

Tz
3 Ry
Rx

Tx
3 Ry
Rx

Plane on
B1

Dim. for Tx , Ty
2
Ang. for Rx, Ry :
2/58 = 0.036

Tx
Ty
4 Rx
Ry

Tx
2
Ty

Center
on B2

7. Final Preparation of the Process Planning File

Job

Sub job

Op.

Turning

M/T

Semi automatic lathe

10

Description

Positioning
clamping

Tooling inspection

Short center

Chuck#3

On (B2) (points
4,5) plane

Jaws
Drill standard

On (B1) points
1,2,3

Tool for facing

Clamping #6

Tool for chamfer

Drilling 18+_0.3

Face rough 14.5+0.5

Face finish

Internal turning 19.40.2

Insert on bar
borer 20H7

Chamfer

Plug gage 20H7

Boring 20H7

Standard surface
finish (visual)

Complementary data:
1. exact sizes of the cuts to be executed, e.g. , for operation 10b, facing rough 14.5 +0.5;
2. details on the machining conditions for each operation (depth of cut, feed, lubrication, type of tool cutting speed, length
of machined segment, machine times);
3. description of the inspection instruments necessary to check the different features and to guarantee their conformity with
the definition drawing; and
4. editing of the process plan file as a comprehensive document.

7.1. Transfer of dimensions and tolerances in design to those in

manufacturing
The dimensions and tolerances in manufacturing are not necessarily the same as in
design.
The dimensions and tolerances on the drawing can be executed directly during the
processing of the part. This is the case in Fig. on slide 33 for the size 13 0.8 during
facing of surface (2).

The dimensions and tolerances on the drawing cannot be translated directly in production.
They are the result of a chain of dimensions obtained during the production processes and
eventually, both their tolerances and their dimensions, are modified. In order to
predetermine the production tolerances, it is necessary to prepare a tolerance charting
table (explained in detail in Chapter 3).
For example, the operations 10b and 10c should produce a final size of 13 0.8. It is assumed that
the roughing operation 10b from the raw material can have a tolerance of 0.5. If the finishing
facing depth has to be between 0.7 and 2.8, it is possible to calculate the dimensions of the rough cut
as follows:
Minimum depth cut in roughing;
= minimum size for roughing (Rmin) - maximum final size
0.7 = Rmin -13.8
Rmin = 13.8+ 0.7 = 14.5
Maximum depth of cut in roughing;
= maximum size of roughing (Rmax) - minimum final size
2.8 = Rmax - (13.0-0.8)
Rmax = 12.2 + 2.8= 15.0
Therefore, the size of the rough cut is:
14.5 +0.5 with a tolerance of 0.5 as requested.

7.2. Determination of machining conditions, times and costs. ISO

3002:1977
1. the cutting speed (vc) and the speed of rotation of the part or of the tool (n) which is
the practical input in machine tools;
2. the feed per revolution (f) or the feed speed in translation of the machine elements

(vf);

3. the depth of cut (a) (or engagement) determining the width of the removed chip;
4. the length (/), width (b) and diameter (d) of the part; and
5. the type of tool chosen and its angles, as well as the type of lubrication.

Computer Aided Process Planning-CAPP

ADVANTAGES
1. It can reduce the skill required of a planner.
2. It can reduce the process planning time.
3. It can reduce both process planning and
manufacturing cost.
4. It can create more consistent plans.
5. It can produce more accurate plans.
6. It can increase productivity.

WHY AUTOMATED
PROCESS PLANNING
Shortening the lead-time
Manufacturability feedback
Lowering the production cost
Consistent process plans

Skills to do manual process planning

may not exist

Variant/derivative/retrieval CAPP approach

Baseline process plans from experienced

planners are entered into the system using
group technology classification and coding
techniques
GT codes for the new part are matched
with GT codes for existing plans. New
plans are created as variants of a baseline
plan. If the codes dont match, and entire
plan is created manually

VARIANT PROCESS PLANNING

part
coding

part
family
formation

standard
plan
preparation

part
coding

part
family
searc h

proces s
plan
retrieval

finished
proces s
plan

Standard
proces s
plans &
individual
proces s
plans

proces s
plan
editing

GROUP TECHNOLOGY BASED RETRIEVAL SYSTEM

VARIANT PROCESS PLANNING

GROUP TECHNOLOGY BASED RETRIEVAL SYSTEM

ADVANTAGES
APPROACH

OF

THE

VARIANT

1.

Once a standard plan has been written, a

variety of components can be planned.

2.

Comparatively simple programming and

installation
(compared
with
generative
systems) is required to implement a planning
system.

3.

The system is understandable, and the

planner has control of the final plan.

4. It is easy to learn, and easy to use.

PROBLEMS
ASSOCIATED
THE VARIANT APPROACH

WITH

1.

The components to be planned are

limited to similar components previously
planned.

2.

Experienced process planners are still

required to modify the standard plan for
the specific component.

3. Details of the plan cannot be generated.

4. Variant planning cannot be used in an

entirely automated manufacturing system,
without additional process planning.

GENERATIVE APPROACH
A system which automatically synthesizes a
process plan for a new component.

MAJOR COMPONENTS:

(i) part description

(ii) manufacturing databases

(iii) decision making logic and

algorithms

Generative CAPP Approach

Generative CAPP Approach

Process plan is automatically generated on

the basis of the same logical procedures
that would be followed by a traditional
process planner
System complex because it must contain
comprehensive and detailed knowledge of
the part as well machine tool capabilities.
Typically utilize an expert system built
upon rules, decision trees, AI techniques

ADVANTAGES
APPROACH
Generate
rapidly;

OF

THE

consistent

GENERATIVE

process

plans

New components can be planned as

easily as existing components;
It has potential for integrating with an
automated manufacturing facility to
provide detailed control information.

SOME RESEARCH ISSUES

Part design representation:

contents, data format

information

Geometric reasoning: feature recognition,

feature extraction, tool approach directions,
feature relations

Process selection: backward planning, tolerance

analysis,
geometric
capability,
process
knowledge, process mechanics
Tool selection: size, length, cut length, shank
length, holder, materials, geometry, roughing,
and finishing tools

SOME RESEARCH ISSUES (continue)

Fixture design: fixture element model, fixturing
knowledge modeling, stability analysis,
friction/cutting force

Tool path planning: algorithms for features,

gauging
and
interference
avoidance
algorithms, automated path generation
Software engineering issues: data structure,
data base, knowledge base, planning
algorithms, user interface, software interface

Additional support systems

Process simulation - putting the
power of graphic animation and
mathematical models together...
Maintenance analysis - tool life,
mean time between failures (MTBF,
MTTR)

Exercise!!